System and method for installing an annular repair rivet through a vertebral body port

ABSTRACT

A two part annulus repair rivet for repairing a defect in the annulus of an intervertebral disc includes a first part delivered through a port and adapted to be positioned at an internal surface of an annulus adjacent a defect and a second part adapted to be positioned on an external surface of the annulus adjacent the defect. The first and second parts are secured together, repairing the defect.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 15/493,794 filed on Apr. 21, 2017, which is, a Continuation ofU.S. patent application Ser. No. 14/280,185 filed on May 16, 2014, whichis a Continuation of U.S. patent application Ser. No. 13/591,961 filedon Aug. 22, 2012, now allowed, which is a Continuation of U.S. patentapplication Ser. No. 12/564,525 filed on Sep. 22, 2009, which issued asU.S. Pat. No. 8,273,110. The content and subject matter of theseapplications are hereby incorporated by reference in their entirety,including all text and figures, for all purposes.

FIELD OF THE INVENTION

The present invention relates to minimally invasive spinal surgery.

BACKGROUND OF THE INVENTION

The annulus of intervertebral discs develop defects or tears, and aportion of the nucleus pulposus can be squeezed toward, into or throughthe defect or tear. This creates pain and discomfort. Methods have beendeveloped to repair these tears in the annulus. These methods includeusing sutures to close the tear. The sutures, however, can fail overtime. Other methods use plugs that are inserted into the tear. Theseplugs, however, are typically inserted from the exterior of the annulusand require difficult positioning or enlarging of the tear toaccommodate insertion of the plug. Some plugs only cover the externalside of the annulus tear.

Therefore, systems and methods are desired for annulus repair that coverboth the internal and external surfaces of the annulus and that providefor access to the internal surface of the annulus for improvedattachment of a repair device to the annulus.

SUMMARY OF THE INVENTION

Exemplary embodiments of the present invention are directed to a methodand system for repairing tears or ruptures in an annulus. Access isprovided to the center or nucleus pulposus of an intervertebral discthrough a port in either one of the vertebrae that are adjacent thatintervertebral disc. Therefore, access to the interior of the disc isprovided without cutting or otherwise further disrupting the integrityof the annulus, maintaining the current status of the annulus. Accessthrough a given vertebra is provided anywhere around the vertebral bodysurface, for example, anterior, lateral, pedicular, A/P, transfacet andend plates. The port terminates at any point inside the annulus.

The port in the vertebra facilitates a bi-directional approach torepairing tears or defects in the intervertebral disc annulus. In thisbi-directional approach, two mating rivets are used to repair the tearin the annulus. One rivet accesses the tear from the exterior surface ofthe annulus, and the other rivet accesses the tear from the interiorsurface of the annulus through the port in the vertebra. Each rivetincludes a flange or wings that are shaped with controlled height thatlimits the range of bend motion in the spine. In addition, the wings arewide enough to act as a barrier between the nucleus and the annulustear.

In accordance with one exemplary embodiment, the present invention isdirected to a method for annulus repair where a port is establishedthrough a vertebral body and vertebral endplate and into a nucleus of anintervertebral disc with an annulus having a tear. The port is createdby drilling a cylindrical shaft through the vertebral body thatintersects the vertebral endplate at an angle less than 90° and greaterthan 0°. The shaft enters an exterior surface of the vertebral bodyopposite the tear.

An internal rivet tool is releasably attached to a distal end of a firstpart of a two-part annulus repair rivet. The distal end is larger thanthe port, and the internal rivet tool is used to push the first partthrough the port, deforming the distal end. The proximal portion of thefirst part that extends from the distal end is inserted through the tearin the annulus until the distal end contacts an interior surface of theannulus. A separate external rivet tool that is releasably attached to adistal end of the second part of the annulus repair rivet positions aproximal portion of the second part that extends from the distal end incontact with the proximal portion of the first part of the annulusrepair rivet.

In one embodiment, each proximal portion is one part of a two-partmechanical fastener. The first part of the two-part mechanical fasteneris a socket containing a plurality of concentric collars, and the secondpart of the two-part mechanical fastener is a stem having a plurality ofbarbs. The first part and second parts of the annulus repair rivet aresecured together by pushing on both the internal and external rivettools to insert the stem in the socket such that barbs on the stemengage collars in the socket. The internal and external rivet tools arereleased from their respective distal ends of annulus repair rivet, andthe internal rivet tool is removed from the port.

In one embodiment, each annulus repair rivet has a distal end and aproximal portion extending from the distal end. Each distal end has anarea sufficient to completely cover the tear and a height equal to aheight of the annulus. In addition, each distal end is formed with acurvature complementing a curvature of the annulus to provide aform-fitting mating between each distal end and the annulus. Inaddition, the proximal portion of the first part of the annulus repairrivet has a length equal to a wall thickness of the annulus, and theproximal portion of the second part of the annulus repair rivet has alength greater than wall thickness of the annulus. In one embodiment,the port in the vertebra is a cylindrical shaft through the vertebralbody, and at least one of a height or a width of the distal end of thefirst part of the annulus repair rivet exceeds a diameter of the port.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a representation of an embodiment of a port drilled through avertebra into an intervertebral disc to repair a tear in an annulus inaccordance with the present invention;

FIG. 2 is a representation of an embodiment of a two-part annulus repairrivet for use in accordance with the present invention;

FIG. 3 is a representation illustrating a perspective view of anembodiment of the attachment of the annulus repair rivet to the annulustear;

FIG. 4 is a representation illustrating a cross section of theintervertebral disc with the annulus repair rivet secured to theannulus;

FIGS. 5A-5B are representations illustrating the annulus repair rivetsecured to the annulus in a neutral state and under deflection of thevertebrae, respectively;

FIG. 6 is a representation illustrating a partial cross section of theintervertebral disc with the annulus repair rivet secured to theannulus;

FIG. 7 is a representation illustrating a cross section of theintervertebral disc with a portion of the nucleus pulposus extendingthrough the annulus tear and a tool inserted through a port in thevertebra; and

FIG. 8 is a representation illustrating a partial cross section of theintervertebral disc with a tool pulling a portion of the nucleuspulposus back through the annulus tear.

DETAILED DESCRIPTION

Referring initially to FIG. 1 , a port 110 is established through one ofthe vertebral bodies 120 adjacent the inter-vertebral disc 130 having anannulus 140 with a tear or defect 150 that is to be repaired. Althoughillustrated in the inferior vertebra, the port 110 can also be locatedin the superior vertebra. Suitable methods for forming the port areknown and available to one of skill in the art and include drilling. Inone embodiment, the port 110 is a cylindrical shaft having a circularcross section. However, the port can have other cross-sectional shapes,for example, a rectangular cross section.

The port extends through the vertebral endplate 160 and into a nucleus170 of the intervertebral disc. In general, the port is formed as ashaft that angled with respect to the endplate of the vertebral body. Inone embodiment, the shaft passes through the vertebral body 120 andintersects the vertebral endplate 160 at an angle 180 less than about90° and greater than about 0°. In another embodiment, the shaftintersects the vertebral endplate at an angle of form about 30° to about45°. Suitable methods for creating the port are known and available toone of skill in the art and include drilling.

The shaft is positioned to provide direct or straight line access to thedefect or tear on the interior surface of the annulus. In oneembodiment, the shaft enters the exterior surface of the vertebral bodyopposite the defect or tear. Therefore, a straight rod can be used topush an annulus repair rivet through the shaft and into contact with theinterior surface of the annulus.

The port is used to facilitate a bi-directional, i.e., internal andexternal, approach to repairing tears or defects in the annulus using atwo-part annulus repair rivet. An exemplary embodiment of a two-partannulus repair rivet 200 for use with the present invention isillustrated in FIG. 2 . The annulus repair rivet includes a first orinternal part 210 that is brought into contact with an internal surface190 (FIG. 1 ) of the annulus through the port and a second or externalpart 220 that is brought into contact with an external surface 195 (FIG.1 ) of the annulus. Suitable materials for the annulus repair rivet arerigid enough to close the annulus defect or tear and to provide adesired amount of cushioning between, adjacent vertebrae and flexibleenough to be deformed when passed through the port. These materialsinclude, but are not limited to, elastomers. The first and second partscan be constructed of the same material or different materials.

In one embodiment, each annulus repair rivet includes a distal end 230and a proximal portion 240 extending from the distal end 230. Eachdistal end has a size or area sufficient to completely cover the annulusdefect or tear 150. Although each distal end 230 could be any shape, forexample circular or oval, preferably, each distal end is generallyrectangular in shape, having a height 260 and a width 250. In oneembodiment, each distal end has a height 260 equal to a height of theannulus 140 as measured between adjacent vertebrae. Therefore, thedistal ends span the entire sides of both the interior and exterior ofthe annulus adjacent the defect or tear, providing for maximum coverageof the defect or tear in the height direction. In addition, the distalends, being made of an elastomeric material that is deformable, providecushioning between adjacent vertebrae and control or limit the range ofmotion between these vertebrae.

When the first and second parts of the annulus repair rivet are broughtinto contact with the interior and exterior surfaces of the annulusrespectively, the distal ends completely cover the annulus defect ortear. In addition, the distal ends are shaped or curved to provide aform-fitting arrangement between the annulus and the annulus repairrivet. This eliminates gaps that could allow the nucleus to emerge pastthe annulus repair rivet. In one embodiment, each distal end has acurvature the complements the curvature of the annulus to provide aform-fitting mating between each distal end and the annulus. As is shownin FIG. 2 , the first and second parts of the annulus repair rivet haveopposite curvatures with regard to the proximal portion. For the firstpart of the annulus repair rivet 210, the proximal end 240 extends froma convex side of the curved distal end 230. For the second part of theannulus repair rivet 220, the distal end 240 extends from a concave sideof the curved distal end 230. Therefore, the first part will mate withthe interior surface of the annulus when the proximal portion extendsthrough the defect or tear, and the second part will mate with theexterior surface of the annulus when the proximal portion extendsthrough the defect or tear.

The proximal portions of the annulus repair rivets of the first andsecond parts contact each other through the annulus defect or tear andare used to secure the two parts together and to hold the annulus repairrivet to the annulus. In one embodiment, each proximal portion includesor is configured as one part of a two-part mechanical fastener.Therefore, securing the first part of the annulus repair rivet to thesecond part of the annulus repair rivet involves engaging the first partof the two-part mechanical fastener in the second part of the two-partmechanical fastener. Suitable two-part mechanical fasteners include, butare not limited to, mating male and female threaded fittings.

According to one variation, the two-part mechanical fastener allows thetwo parts of the annulus repair rivet to be pressed together andsecured. Referring to FIGS. 2 and 6 , in one embodiment the proximalportion 240 of the first part 210 of the two-part mechanical fastener isa female fitting or socket 610 having a cylindrical shaft and includinga plurality of concentric collars 620 extending into the cylindricalshaft and spaced along its length. The proximal portion 240 of thesecond part 220 of the two-part mechanical fastener is a male fitting orstem having a plurality of wedge-shaped barbs 630. Each barb extendsaround the outer circumference of the proximal portion, and theplurality of barbs is spaced along the length of the proximal portion.Although illustrated with two barbs and two collars, the number of barbsand collars can be varied. For example, a larger number of barbs andcollars provides for a finer degree of fit between the annulus repairrivet and the thickness of the annulus.

In order to secure the first part of the annulus repair rivet to thesecond part, the stem is inserted into the socket such that the barbsengage the collars. The proximal portion 240 of the first part 210 has alength extending from the distal end 230 that is substantially equal tothe wall thickness of the annulus. Therefore, when the first and secondparts are pushed together, the proximal portion of the first part doesnot extend through the defect or tear past the exterior surface of theannulus. The proximal portion 240 of the second part 220 has a lengthextending from the distal end 230 that is longer than the wall thicknessof the annulus. Therefore, when the first and second parts are pushedtogether, the proximal portion of the second part extends into thedistal end of the first part. In one embodiment, the proximal portion ofthe second part extends completely through the distal end of the firstpart, facilitating removal or disengagement of the stem from the socket.In one variation, the proximal portions 240 extend generally orthogonalto the distal ends, although they may be angled to accommodate theinsertion trajectory or angle of the port, for example.

In one embodiment, the stem can also include a central slot 640. Thisallows the stem to deform when being inserted into or removed from thesocket 610. In addition, each distal end can have one or more grooves270 and ridges 280 (FIG. 2 ) on a surface opposite the surface thatcontacts the annulus. These grooves and ridges provide points ofattachment or grips for tools used to attached the annulus repair rivetto the annulus.

Referring to FIG. 3 , after the port 110 is created in the vertebralbody 120 from a point opposite the defect or tear 150 through thevertebral endplate and into the interior of the intervertebral disc 130,an internal rivet tool 310 is releasably attached to the first part 210of the two-part annulus repair rivet, and a separate external rivet tool320 is releasably attached to the second part 220 of the two-partannulus repair rivet. The rivet tools grip the grooves and ridges on thedistal end of the first and second parts. In one embodiment, both theinternal and external rivet tools are rigid cylindrical rods that canpush the two parts the annulus repair rivet together.

The internal rivet tool 310 has a diameter small enough to pass throughthe shaft and a length long enough to extend completely through the portand to position the first part of the annulus repair rivet at aninternal surface 190 of the annulus adjacent the defect or tear 150.Since the port 110 is a cylindrical shaft through the vertebral body andat least one of the height 250 or a width 260 of the distal end of thefirst part 210 of the annulus repair rivet can exceed the diameter ofthe port, the internal rivet tool passes the first part of the two-partannulus repair rivet through the port by pushing the first part throughthe port and deforming the larger distal end. The distal end reformswhen it emerges in the space internal to the annulus. The internal rivettool inserts the proximal portion of the first part that extends fromthe distal end through the defect or tear in the annulus until thedistal end contacts an interior surface of the annulus.

The external rivet tool 320 positions the second part of the two-partannulus repair rivet at an external surface of the annulus adjacent thedefect or tear. Therefore, the proximal portion of the second part is incontact with the proximal portion of the first part of the annulusrepair rivet.

Referring to FIG. 4 , the first part 210 of the annulus repair rivet issecured to the second part 220 of the annulus repair rivet to close thedefect or tear in the annulus. Securing is accomplished by pushing onboth the internal and external rivet tools to insert the stem in thesocket such that the barbs engage the collars. The internal and externalrivet tools are then released from the respective distal ends of theannulus repair rivets, and the internal rivet tool is removed from theport. As illustrated in FIG. 5 , the annulus repair rivet 200 isattached to the annulus, sealing the annulus defect or tear. The distalends of the first and second parts can deform under the relative motionbetween the adjacent vertebrae, providing cushioning and controlling therange of motion. The port 110 is sealed using methods known andavailable to one of skill in the art.

Referring to FIG. 7 , a portion 720 of the nucleus pulposus 170 may haveemerged from the intervertebral disc 130 through the defect or tear 150in the annulus 140. Therefore, this portion 720 may be removed from thedefect or tear before the two-part annulus repair rivet is used torepair the defect or tear. In one embodiment, after the port 110 iscreated in the vertebra, a tool 710 is inserted through the port 110,into the nucleus pulposus 170. The tool is sized to fit through the portand to grip the emerging portion 720 of the nucleus pulposus. One ofsuch suitable tools may include forceps. The tool 710 is extendedthrough the defect or tear 150 to grip the emerging portion 720 and topull that portion back through the defect or tear 150 to the interior ofthe disc as illustrated in FIG. 8 . The tool is removed, and the annulusrepair rivet can then be attached as described herein. It may also benecessary to remove a portion of the nucleus pulposus through the port110 to facilitate insertion of the first part of the two-part annulusrepair rivet. In another embodiment, such a tool may be used with ahealthy annulus and/or independent of the annulus to remove a defectivenucleus as desired. In this regard, the aforementioned method may beused to access and remove the nucleus without breaching the annuluswhatsoever, thereby maintaining the integrity of the annulus. Further,an artificial nucleus material may be inserted through the same accessport.

While it is apparent that the illustrative embodiments of the inventiondisclosed herein fulfill the objectives of the present invention, it isappreciated that numerous modifications and other embodiments may bedevised by those skilled in the art. Additionally, feature(s) and/orelement(s) from any embodiment may be used singly or in combination withother embodiment(s) and steps or elements from methods in accordancewith the present invention can be executed or performed in any suitableorder. Therefore, it will be understood that the appended claims areintended to cover all such modifications and embodiments, which wouldcome within the spirit and scope of the present invention.

What is claimed is:
 1. A method for annulus repair, the methodcomprising: drilling a shaft at an exterior surface of the vertebralbody opposite a defect through which a portion of the nucleus emergesfor purposes of establishing a port; inserting an internal tool throughthe shaft and into the nucleus; gripping the emerging portion with theinserted internal tool; pulling the gripped portion back into thenucleus; removing the inserted internal tool from the shaft; repairingthe defect through the shaft after the emerging portion has been pulledback into the nucleus.
 2. The method of claim 1, wherein the step ofdrilling a shaft includes establishing the port without breaching theannulus.
 3. The method of claim 1, wherein: the step of insertingincludes inserting forceps through the port; and the step of grippingincludes gripping the emerging portion with the forceps.
 4. The methodof claim 1, further comprising inserting through the port a plug toblock the defect.
 5. The method of claim 1, after the plug has beeninserted, further comprising positioning the plug at an internal surfaceof the annulus adjacent the defect.
 6. The method of claim 1, furthercomprising inserting through the port a two part annulus repair rivet toblock the defect by: using an internal rivet tool to pass a first partof the two part annulus repair rivet through the port and to positionthe first part of the annulus repair rivet at an internal surface of theannulus adjacent the defect; using an external rivet tool separate fromthe internal rivet tool to position a second part of the two partannulus repair rivet at an external surface of the annulus adjacent thedefect; and securing the first part of the annulus repair rivet to thesecond part of the annulus repair rivet to close the defect in theannulus.
 7. The method of claim 6, wherein: each annulus repair rivetcomprises a distal end and a proximal portion extending from the distalend, each distal end having an area sufficient to completely cover thedefect; and each proximal portion comprises one part of the two-partmechanical fastener; and the step of securing the first part of theannulus repair rivet to the second part of the annulus repair rivetcomprises engaging a first part of the two-part mechanical fastener in asecond part of the two-part mechanical fastener.
 8. The method of claim7, wherein the first part of the two-part mechanical fastener comprisesa socket containing a plurality of concentric collars and the secondpart of the two-part mechanical fastener comprises a stem having aplurality of barbs, and the step of securing the first part of theannulus repair rivet to the second part comprises inserting the stem inthe socket such that the barbs engage the collars.
 9. The method ofclaim 6, wherein the step of using an internal rivet tool to pass afirst part of a two part annulus repair rivet through the port furthercomprises using the internal rivet tool releasably attached to a distalend of the first part that is larger than the port to push the firstpart through the port, deforming the distal end and to insert a proximalportion of the first part that extends from the distal end through thedefect in the annulus until the distal end contacts an interior surfaceof the annulus.
 10. The method of claim 6, wherein using an externalrivet tool separate from the internal rivet tool to position a secondpart of the two part annulus repair rivet further comprises using theexternal rivet tool releasably attached to a distal end of the secondpart to position a proximal portion of the second part that extends fromthe distal end in contact with the proximal portion of the first part ofthe annulus repair rivet.
 11. The method of claim 6, wherein theproximal portion of the first part of the annulus repair rivet comprisesa socket containing a plurality of concentric collars and the proximalportion of the second part of the annulus repair rivet comprises a stemhaving a plurality of barbs, and the step of securing the first part ofthe annulus repair rivet to the second part comprises pushing on boththe internal and external rivet tools to insert the stem in the socketsuch that the barbs engage the collars.
 12. A method for annulus repair,the method comprising: establishing a port through a vertebral body andinto a nucleus of an intervertebral disc having an annulus and anemerging portion emerging outside of the nucleus through a defect;inserting an internal tool through the port and into the nucleus;gripping a portion of the nucleus with the inserted internal tool;pulling the gripped portion to bring the emerging portion back into thenucleus; repairing the defect after the emerging portion has beenbrought back into the nucleus; and inserting through the port a two partannulus repair rivet to block the defect by: using an internal rivettool to pass a first part of the two part annulus repair rivet throughthe port and to position the first part of the annulus repair rivet atan internal surface of the annulus adjacent the defect; using anexternal rivet tool separate from the internal rivet tool to position asecond part of the two part annulus repair rivet at an external surfaceof the annulus adjacent the defect; and securing the first part of theannulus repair rivet to the second part of the annulus repair rivet toclose the defect in the annulus.
 13. The method of claim 12, wherein thestep of establishing includes establishing the port without breachingthe annulus.
 14. The method of claim 12, wherein the step of insertingincludes inserting forceps through the port.
 15. The method of claim 12,wherein the step of gripping includes gripping the emerging portion. 16.The method of claim 12, further comprising inserting through the port aplug to block the defect.
 17. The method of claim 16, after the plug hasbeen inserted, further comprising positioning the plug at an internalsurface of the annulus adjacent the defect.
 18. The method of claim 12,wherein the step of establishing the port includes drilling a shaftthrough the vertebral body that intersects the vertebral endplate at anangle less than 90 degrees and greater than 0 degrees.
 19. The method ofclaim 18, wherein drilling a shaft includes drilling the shaft at anexterior surface of the vertebral body opposite the defect.